Compression and stretch resistant components and cables for oilfield applications

ABSTRACT

An opto-electrical cable may include an opto-electrical cable core and a polymer layer surrounding the opto-electrical cable core. The opto-electrical cable core may include a wire, one or more channels extending longitudinally along the wire, and one or more optical fibers extending within each channel. The opto-electrical cable may be made by a method that includes providing a wire having a channel, providing optical fibers within the channel to form an opto-electrical cable core, and applying a polymer layer around the opto-electrical cable core. A multi-component cable may include one or more electrical conductor cables and one or more opto-electrical cables arranged in a coax, triad, quad configuration, or hepta configuration. Deformable polymer may surround the opto-electrical cables and electrical conductor cables.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

FIELD

Embodiments of the present disclosure generally relate to cables forproviding electrical power and telemetry to downhole tools.

BACKGROUND

Certain opto-electrical cables for providing both electrical power andtelemetry to downhole tools include a tube formed ofsemicircular-profile wires that surround optical fibers. Traditionally,such opto-electrical cables, when subjected to longitudinal strainand/or compressive forces, are subject to “milking,” where filler geland/or optical fibers within the tube are squeezed out of the tube.Manufacturing imperfections may increase the occurrence of milking.

SUMMARY

The present disclosure provides for an opto-electrical cable. Theopto-electrical cable includes an opto-electrical cable core, and apolymer layer longitudinally and circumferentially surrounding theopto-electrical cable core. The opto-electrical cable core includes awire, at least one channel formed within the wire and extendinglongitudinally along the wire, and optical fibers extendinglongitudinally within each channel.

The present disclosure provides for a multi-component cable. Themulti-component cable includes electrical conductor cables andopto-electrical cables. Deformable polymer longitudinally andcircumferentially surrounds the opto-electrical cables and theelectrical conductor cables. The opto-electrical cables and theelectrical conductor cables are arranged within the deformable polymerin a coax configuration, a triad configuration, a quad configuration, ora hepta configuration. Each opto-electrical cable includes anopto-electrical cable core. Each opto-electrical cable core includes awire, at least one channel formed within the wire and extendinglongitudinally along the wire, and optical fibers extendinglongitudinally within each channel. A polymer layer longitudinally andcircumferentially surrounds each opto-electrical cable core.

The present disclosure provides for a method. The method includesproviding a wire having at least one channel extending longitudinallywithin and along the wire. The method includes providing optical fibersextending longitudinally within each channel. The wire and the opticalfibers form an opto-electrical cable core. The method includes applyinga polymer layer longitudinally and circumferentially surrounding theopto-electrical cable core to form an opto-electrical cable.

BRIEF DESCRIPTION OF DRAWINGS

The present disclosure may be understood from the following detaileddescription when read with the accompanying figures. It is emphasizedthat, in accordance with the standard practice in the industry, variousfeatures may not be drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 depicts a cross-sectional view of an opto-electrical cableincluding a wire having a channel and cap configuration in accordancewith certain embodiments of the present disclosure.

FIGS. 1A-1F depicts cross-sectional views showing manufacture of theopto-electrical cable of FIG. 1 in accordance with certain embodimentsof the present disclosure.

FIG. 2 depicts a cross-sectional view an opto-electrical cable includinga wire having multiple channels in accordance with certain embodimentsof the present disclosure.

FIGS. 2A-2D depicts cross-sectional views showing manufacture of theopto-electrical cable of FIG. 2 in accordance with certain embodimentsof the present disclosure.

FIG. 3 depicts a cross-sectional view an opto-electrical cable includinga wire having a single channel in accordance with certain embodiments ofthe present disclosure.

FIGS. 3A-3D depicts cross-sectional views showing manufacture of theopto-electrical cable of FIG. 3 in accordance with certain embodimentsof the present disclosure.

FIG. 4 depicts a cross-sectional view an opto-electrical cable includinga wire having a single channel and a planar base in accordance withcertain embodiments of the present disclosure.

FIGS. 4A-4D depicts cross-sectional views showing manufacture of theopto-electrical cable of FIG. 4 in accordance with certain embodimentsof the present disclosure.

FIG. 5 depicts a cross-sectional view an opto-electrical cable includinga wire having a single channel and a C-shaped profile in accordance withcertain embodiments of the present disclosure.

FIGS. 5A-5E depicts cross-sectional views showing manufacture of theopto-electrical cable of FIG. 5 in accordance with certain embodimentsof the present disclosure.

FIGS. 6A-6D depicts cross-sectional views of opto-electrical cableshaving completion layers in accordance with certain embodiments of thepresent disclosure.

FIGS. 7A-7D depicts cross-sectional views of additional embodiments ofopto-electrical cables having completion layers in accordance withcertain embodiments of the present disclosure.

FIGS. 8A-8D depicts cross-sectional views of additional embodiments ofopto-electrical cables having completion layers in accordance withcertain embodiments of the present disclosure.

FIGS. 9A-9D depicts cross-sectional views of additional embodiments ofopto-electrical cables having completion layers in accordance withcertain embodiments of the present disclosure.

FIGS. 10A-10D depicts cross-sectional views of additional embodiments ofopto-electrical cables having completion layers in accordance withcertain embodiments of the present disclosure.

FIGS. 11A-11D depicts cross-sectional views showing manufacture of anopto-electrical cable having a completion layer in accordance withcertain embodiments of the present disclosure.

FIG. 12 depicts a cross-sectional view of a multi-component cable inaccordance with certain embodiments of the present disclosure.

FIGS. 13A-13C depicts cross-sectional views of jacketed multi-componentcables having arch-profile wires in accordance with certain embodimentsof the present disclosure.

FIGS. 14A-14H depicts cross-sectional views showing manufacture of ajacketed multi-component cable having arch-profile wires in accordancewith certain embodiments of the present disclosure.

FIGS. 15A-15C depicts cross-sectional views of jacketed multi-componentcables having a layer of corrugated metallic tape in accordance withcertain embodiments of the present disclosure.

FIGS. 16A-16I depicts cross-sectional views showing manufacture ofjacketed multi-component cables having a layer of corrugated metallictape in accordance with certain embodiments of the present disclosure.

FIGS. 17A-17C depicts cross-sectional views of jacketed multi-componentcables having a layer of metallic cladding tape in accordance withcertain embodiments of the present disclosure.

FIGS. 18A-18H depicts cross-sectional views showing manufacture ofjacketed multi-component cables having a layer of metallic cladding tapein accordance with certain embodiments of the present disclosure.

FIGS. 19A-19C depicts cross-sectional views of jacketed multi-componentcables having a layer of hard polymer in accordance with certainembodiments of the present disclosure.

FIGS. 20A-20G depicts cross-sectional views showing manufacture ofjacketed multi-component cables having a layer of hard polymer inaccordance with certain embodiments of the present disclosure.

DETAILED DESCRIPTION

A detailed description will now be provided. The following disclosureincludes specific embodiments, versions and examples, but the disclosureis not limited to these embodiments, versions or examples, which areincluded to enable a person having ordinary skill in the art to make anduse the disclosure when the information in this application is combinedwith available information and technology. In addition, the presentdisclosure may repeat reference numerals and/or letters in the variousexamples. This repetition is for the purpose of simplicity and clarityand does not in itself dictate a relationship between the variousembodiments and/or configurations discussed.

Various terms as used herein are shown below. To the extent a term usedin a claim is not defined below, it should be given the broadestdefinition persons in the pertinent art have given that term asreflected in printed publications and issued patents. Further, unlessotherwise specified, all compounds described herein may be substitutedor unsubstituted and the listing of compounds includes derivativesthereof.

Further, various ranges and/or numerical limitations may be expresslystated below. It should be recognized that unless stated otherwise, itis intended that endpoints are to be interchangeable. Where numericalranges or limitations are expressly stated, such express ranges orlimitations should be understood to include iterative ranges orlimitations of like magnitude falling within the expressly stated rangesor limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.;greater than 0.10 includes 0.11, 0.12, 0.13, etc.).

Embodiments of the present disclosure may include an opto-electricalcable for providing electrical power, data transmission, distributedsensing capabilities, or combinations thereof. For example and withoutlimitation, the opto-electrical cable may be used to provide electricalpower, data transmission, distributed sensing capabilities, orcombinations thereof to downhole tools within a wellbore. In certainembodiments, the opto-electrical cable may include stable, durable,stretch-resistant and compression-resistant opto-electrical cable coresadapted to resist milking.

FIG. 1 depicts an embodiment of opto-electrical cable 100 a.Opto-electrical cable 100 a may include base wire 104. Base wire 104 mayinclude channel 106 formed within and extending along a longitudinalaxis of base wire 104. In certain embodiments, base wire 104 has apartial-circular-profile. Base wire 104 may be a conductive metal wire.For example and without limitation, base wire 104 may be a copper wire,a copper alloy wire, a steel wire, or an aluminum wire. In certainembodiments, base wire 104 has base wire mating face 100 a. Base wiremating face 108 a may extend from channel edge 109 to outer wirecircumference 109 a of base wire 104. Channel 106 may be formed withinbase wire 104 between two portions of base wire mating face 100 a. Insome embodiments, base wire mating face 108 a is a planar surface. Oneor more optical fibers 110 may extend longitudinally within channel 106.In certain embodiments, optical fibers 110 may be composed of acrylatefibers, polyimide fibers, or silicone perfluoroalkoxy (PFA) fibers. Incertain embodiments, filler 112 may encase optical fibers 110 withinchannel 106. Filler 112 may provide protective cushioning to opticalfibers 110. In some embodiments, filler 112 is a soft gel filler, suchas a silicon polymer gel. Opto-electrical cable 100 a may include capwire 104 a. Cap wire 104 a may be formed of the same or differentconductive materials as base wire 104. In some embodiments, cap wire 104a has a semicircular outer profile. Cap wire 104 a may be mechanicallycoupled with base wire 104. For example and without limitation, cap wire104 a may include cap wire mating face 108 b and tab 114 extending fromcap wire mating face 108 b. In some embodiments, tab 114 extends fromcap wire mating face 108 b between two portions cap wire mating face 108b. Tab 114 may be sized and shaped to fit within channel 106 in basewire 104. Tab 114 may extend at least partially into channel 106 andlongitudinally along cap wire 104 a. With optical fibers 110 and filler112 within channel 106, tab 114 of cap wire 104 a may be mechanicallycoupled into channel 106 of base wire 104. For example and withoutlimitation, tab 114 may be close fit, location fit, or interference fitwithin channel 106. In some embodiments, tab 114 may be press fit orshrink fit into channel 106. When cap wire 104 a is mechanically coupledwith base wire 104, cap wire mating face 108 b may be in contact withbase wire mating face 100 a. In some embodiments, cap wire mating face108 b is a planar surface. Cap wire 104 a may enclose and/or sealchannel 106. Opto-electrical cable 100 a may include one or more polymerlayers 118 encasing base wire 104 and cap wire 104 a. In someembodiments, polymer layer 118 includes one or more layers of tape. Forexample and without limitation, the tape of polymer layer 118 may be apolyetheretherketone (PEEK) tape. In some embodiments, polymer layer 118includes one or more layers of extruded polymer. Polymer layer 118 mayretain optical fibers 110 and filler 112 in position within channel 106.In certain embodiments, opto-electrical cable 100 a has acircular-profile. In operation, when opto-electrical cable 100 a issubjected to compressive forces and/or longitudinal strain, cap wire 104a may be remain mechanically coupled with base wire 104. For example,tab 114 may remain mechanically coupled within channel 106, preventingor reducing the occurrence of milking.

FIGS. 1A-1F depict manufacture of opto-electrical cable 100 a inaccordance with this disclosure. Base wire 104 having base wire matingface 108 a and channel 106 may be provided, as shown in FIG. 1A. One ormore optical fibers 110 may be placed within channel 106, as shown inFIG. 1B. Filler 112 may be placed into channel 106, encasing opticalfibers 110, as shown in FIG. 1C. Cap wire 104 a having tab 114 and capwire mating face 108 b may be provided, as shown in FIG. 1D. Cap wire104 a may be mechanically coupled with base wire 104 by engaging tab 114into channel 106 and engaging base wire mating face 108 a with cap wiremating face 108 b, enclosing channel 106 and forming opto-electricalcable core 116 a, as shown in FIG. 1E. One or more polymer layers 118may by wrapped around or extruded over opto-electrical cable core 116 a,encasing opto-electrical cable core 116 a and forming opto-electricalcable 100 a, as shown in FIG. 1F. Polymer layer 118 may longitudinallyand circumferentially surround opto-electrical cable core 116 a.

FIG. 2 depicts another embodiment of an opto-electrical cable consistentwith this disclosure. Opto-electrical cable 100 b may include wire 104b. In certain embodiments, wire 104 b has a circular-profile. Wire 104 bmay be composed of the same or different materials as base wire 104.Wire 104 b may have one or more channels 106, two or more channels 106,or three or more channels 106 formed within and extending along alongitudinal axis of wire 104 b. For example and without limitation,wire 104 b is depicted in FIG. 2 as having three channels 106. Channels106 may be formed within wire 104 b between two portions of outer wirecircumference 109 of wire 104 b. In embodiments of wire 104 b havingmultiple channels 106, channels 106 may be uniformly spaced about outerwire circumference 109. In other embodiments of wire 104 b havingmultiple channels 106, channels 106 are non-uniformly spaced about outerwire circumference 109. In some embodiments, channels 106 may extendparallel with a longitudinal axis of wire 104 b along the length of wire104 b. In other embodiments, channels 106 may spiral helically about thelongitudinal axis of wire 104 b. One or more optical fibers 110 mayextend longitudinally within each channel 106 of wire 104 b. Opticalfibers 110 may be composed of the same materials or different materialsas discussed with respect to FIG. 1. In certain embodiments, filler 112may be encase optical fibers 110 within channels 106. Filler 112 may bethe same as or different than filler 112 described with respect toFIG. 1. In certain embodiments, filler 112 encases the entirety of wire104 b (not shown). In other embodiments, filler 112 does not encase theentirety of wire 104 b. Opto-electrical cable 100 b may include one ormore polymer layers 118 encasing wire 104 b and channels 106. Polymerlayer 118 may be the same as or different than polymer layer 118 asdescribed with respect to FIG. 1. Polymer layer 118 may surround channel106 and/or filler 112 within channel 106. In certain embodiments,opto-electrical cable 100 b has a circular-profile.

FIGS. 2A-2D depict manufacture of opto-electrical cable 100 b inaccordance with this disclosure. Wire 104 b having one or more channels106 may be provided, as shown in FIG. 2A. One or more optical fibers 110may be placed within each channel 106 of wire 104 b, as shown in FIG.2B. Filler 112 may be placed within each channel 106, encasing opticalfibers 110 and forming opto-electrical cable core 116 b, as shown inFIG. 2C. One or more polymer layers 118 may be wrapped around orextruded over opto-electrical cable core 116 b, forming opto-electricalcable 100 b, as shown in FIG. 2D. Polymer layer 118 may longitudinallyand circumferentially surround opto-electrical cable core 116 b.

FIG. 3 depicts another embodiment of an opto-electrical cable inaccordance with this disclosure. Opto-electrical cable 100 c may includewire 104 c. In certain embodiments, wire 104 c has a circular-profilewith circular or arcuate outer wire circumference 123. Wire 104 c may becomposed of the same or different materials as base wire 104. Wire 104 cmay have a single channel 106. Channel 106 may be formed within wire 104c between two portions of outer wire circumference 123. Channel 106 mayextend along a longitudinal axis of wire 104 c. In some embodiments,channel 106 may extend parallel with the longitudinal axis of wire 104 calong the length of wire 104 c. In other embodiments, channel 106 mayspiral helically about longitudinal axis of wire 104 c. One or moreoptical fibers 110 may extend longitudinally within channel 106 of wire104 c. Optical fibers 110 may be composed of the same materials ordifferent materials as discussed with respect to FIG. 1. In certainembodiments, filler 112 may encase optical fibers 110 within channel106. Filler 112 may be the same as or different than filler 112described with respect to FIG. 1. In certain embodiments, filler 112encases the entirety of wire 104 c (not shown). In other embodiments,filler 112 does not encase the entirety of wire 104 c. Opto-electricalcable 100 c may include one or more polymer layers 118 encasing wire 104c and channel 106. Polymer layer 118 may be the same as or differentthan polymer layer 118 as described with respect to FIG. 1. Polymerlayer 118 may surround channels 106 and/or filler 112 within channels106. In certain embodiments, opto-electrical cable 100 c has acircular-profile.

FIGS. 3A-3D depict manufacture of opto-electrical cable 100 c inaccordance with this disclosure. Wire 104 c with outer wirecircumference 123 and channel 106 may be provided, as shown in FIG. 3A.One or more optical fibers 110 may be placed within channel 106 of wire104 c, as shown in FIG. 3B. Filler 112 may be placed within channel 106,encasing optical fibers 110 and forming opto-electrical cable core 116c, as shown in FIG. 3C. One or more polymer layers 118 may be wrappedaround or extruded over opto-electrical cable core 116 c, formingopto-electrical cable 100 c, as shown in FIG. 3D. Polymer layer 118 maylongitudinally and circumferentially surround opto-electrical cable core116 c.

FIG. 4 depicts another embodiment of an opto-electrical cable inaccordance with this disclosure. Opto-electrical cable 100 d may includewire 104 d. In certain embodiments, wire 104 d has a hexagonal-profileor an approximately hexagonal-profile. Wire 104 d may be composed of thesame or different materials as base wire 104. Wire 104 d may have base120 formed along a circumference of wire 104 d. In some embodiments,base 120 is a planar surface formed on one side of wire 104 d. Base 120may extend along a longitudinal axis of wire 104 d. Wire 104 d may havea single channel 106. In some embodiments, wire 104 d may have multiplechannels (not shown). In certain embodiments, channel 106 of wire 104 dmay be formed within wire 104 d between two portions of outer wirecircumference 122 of wire 104 d and opposite of base 120. Channel 106may extend along a longitudinal axis of wire 104 d. In some embodiments,channel 106 may extend parallel to the longitudinal axis of wire 104 dalong the length of wire 104 d. In certain embodiments, channel 106 ofwire 104 d has a circular-profile or semi-circular-profile. In certainembodiments, opto-electrical cable 100 d has a circular-profile. Incertain embodiments, sides of outer wire circumference 122 have anon-circular profile, such that sides of wire 104 d are at leastpartially flattened. One or more optical fibers 110 may extendlongitudinally within channel 106 of wire 104 d. Optical fibers 110 maybe composed of the same materials or different materials as discussedwith respect to FIG. 1. In certain embodiments, filler 112 may encaseoptical fibers 110 within channel 106. Filler 112 may be the same as ordifferent than filler 112 described with respect to FIG. 1. In certainembodiments, filler 112 encases the entirety of wire 104 d (not shown).In other embodiments, filler 112 does not encase the entirety of wire104 d. Opto-electrical cable 100 d may include one or more polymerlayers 118 encasing wire 104 d and channel 106. Polymer layer 118 may bethe same as or different than polymer layer 118 as described withrespect to FIG. 1. Polymer layer 118 may surround channel 106 and/orfiller 112 within channel 106.

FIGS. 4A-4D depict manufacture of opto-electrical cable 100 d inaccordance with this disclosure. Wire 104 d having base 120, channel106, and outer wire circumference 122 may be provided, as shown in FIG.4A. Wire 104 d may be held securely in place in a desired position andlocation and prevented from moving from the desired position andlocation. For example and without limitation, base 120 may be engaged ona surface (not shown) and sides of outer wire circumference 122 of wire104 d may be held to secure wire 104 d in the desired position andlocation. With wire 104 d secured in the desired position and location,one or more optical fibers 110 may be placed within channel 106 of wire104 d, as shown in FIG. 4B. Filler 112 may be placed within channel 106,encasing optical fibers 110 and forming opto-electrical cable core 116d, as shown in FIG. 4C. One or more polymer layers 118 may be wrappedaround or extruded over opto-electrical cable core 116 d, formingopto-electrical cable 100 d, as shown in FIG. 4D. Polymer layer 118 maylongitudinally and circumferentially surround opto-electrical cable core116 d.

FIG. 5 depicts another embodiment of an opto-electrical cable inaccordance with this disclosure. Opto-electrical able 100 e may includewire 104 e. In certain embodiments, wire 104 e has a C-shaped-profile.Wire 104 e may be formed of the same or different materials as base wire104. Wire 104 e may have a single channel 106. Channel 106 may be formedwithin and extend along a longitudinal axis of wire 104 e. In someembodiments, channel 106 may extend parallel with the longitudinal axisof wire 104 e along the length of wire 104 e. In certain embodiments,channel 106 is formed within a central interior of wire 104 e, andchannel 106 may concentrically aligned with the longitudinal axis ofwire 104 e. Channel 106 may have opening 126 formed between two portionsof outer wire circumference 127. One or more optical fibers 110 mayextend longitudinally within channel 106 of wire 104 e. Optical fibers110 may be composed of the same materials or different materials asdiscussed with respect to FIG. 1. Filler 112 may encase optical fibers110 within channel 106. Filler 112 may be the same as or different thanfiller 112 described with respect to FIG. 1. Plug 124 may bemechanically coupled with and/or chemically bonded to wire 104 e atopening 126 of channel 106. In certain embodiments, plug 124 may be ahard polymer plug. For example and without limitation, plug 124 may becomposed of a polymer or gel having a higher viscosity than filler 112.Plug 124 may enclose and/or seal filler 112 and/or optical fibers 110within channel 106. In some embodiments, a layer of material formingplug 124 is located circumferentially about wire 104 e (not shown).Opto-electrical cable 100 e may include one or more polymer layers 118encasing wire 104 e and plug 124. Polymer layer 118 may be the same asor different than polymer layer 118 as described with respect to FIG. 1.Polymer layer 118 may surround opening 126 of channel 106 and/or filler112 within channel 106. In certain embodiments, opto-electrical cable100 e has a circular-profile.

FIG. 5A-5E depict manufacture of opto-electrical cable 100 e inaccordance with this disclosure. Wire 104 e having channel 106 may beprovided, as shown in FIG. 5A. One or more optical fibers 110 may beplaced within channel 106 of wire 104 e, as shown in FIG. 5B. Filler 112may be placed within channel 106, encasing optical fibers 110, as shownin FIG. 5C. Plug 124 may be mechanically coupled with and/or chemicallybonded to wire 104 e at opening 126 of channel 106, formingopto-electrical cable core 116 e, as shown in FIG. 5D. For example andwithout limitation, plug 124 may be mechanically coupled with and/orchemically bonded to wire 104 e prior to filler 112 (e.g., siliconpolymer gel) curing within channel 106. In operation, when plug 124 ismechanically coupled with and/or chemically bonded to wire 104 e, plug124 may restrict movement of optical fibers 110 during and/or aftercuring of filler 112 within channel 106, preventing or reducing theoccurrence of milking. In certain embodiments, a quantity of materialforming plug 124 is applied in a layer circumferentially about wire 104e (not shown). One or more polymer layers 118 may be wrapped around orextruded over opto-electrical cable core 116 e, forming opto-electricalcable 100 e, as shown in FIG. 5E. Polymer layer 118 may longitudinallyand circumferentially surround opto-electrical cable core 116 e.

In certain embodiments, the opto-electrical cable core includes a singlewire, as is depicted in FIGS. 2-5E. In other embodiments, theopto-electrical cable core includes at least two wires, as is depictedin FIGS. 1-1F. In operation, optical fibers 110 may be used to transmitdata, and wires (e.g., 104, 104 a-104 e) may be used to transmitelectrical power and/or data. For example and without limitation, wires(e.g., 104, 104 a-104 e) may provide electrical power downhole to atoolstring, and coiled tubing or casing may be used to complete thecircuit. Optical fibers 110 may be used for telemetry and/or as sensorsto measure distributed temperature, pressure, and longitudinal stain,for example.

In some embodiments, polymer layer 118 may provide insulation to opticalfibers 110 and wires (e.g., 104, 104 a-104 e). In certain embodiments,micro-bundles of optical fibers 110 may be contained within channels 106of wires (e.g., 104, 104 a-104 e), increasing the number of opticalfibers 110 within channels 106 of wires (e.g., 104, 104 a-104 e).Bundled optical fibers 110 may include single mode and/or multi-modeoptical fibers. In some embodiments, optical fibers 110 are cabled in ahelix, which may increase the longitudinal strain optical fibers 110 cansustain. In some embodiments, optical fibers 110 are uncoated opticalfibers. In other embodiments, optical fibers 110 are coated opticalfibers.

Each of opto-electrical cables 100 a-100 e may include one or morecompletion layers, forming a completed opto-electrical cable. FIGS. 6A,6B, 6C and 6D depict embodiments of completed opto-electrical cables inaccordance with this disclosure. As shown in FIG. 6A, completedopto-electrical cables 500 a may include opto-electrical cable core 116a longitudinally and circumferentially surrounded by one or more polymerlayers 118. As shown in FIG. 6B, completed opto-electrical cables 500 bmay include opto-electrical cable core 116 b longitudinally andcircumferentially surrounded by one or more polymer layers 118. As shownin FIG. 6C, completed opto-electrical cables 500 c may includeopto-electrical cable core 116 c longitudinally and circumferentiallysurrounded by one or more polymer layers 118. As shown in FIG. 6D,completed opto-electrical cables 500 d may include opto-electrical cablecore 116 e longitudinally and circumferentially surrounded by one ormore polymer layers 118. Completed opto-electrical cables 500 a-500 dmay each include layer of cladding 130 longitudinally andcircumferentially surrounding polymer layers 118, as shown in FIGS.6A-6D, respectively. For example and without limitation, cladding 130may be composed of a metal, such as Zn, Ni, Mo or Fe. While completedopto-electrical cables 500 a-500 d are shown as having opto-electricalcables 100 a, 100 b, 100 c and 100 e, one skilled in the art with theaid of the present disclosure would understand that cladding 130 mayalso be applied to opto-electrical cables 100 d to form a completedopto-electrical cable.

FIGS. 7A, 7B, 7C and 7D depict additional embodiments of completedopto-electrical cables in accordance with this disclosure. Completedopto-electrical cable 500 e may include opto-electrical cable core 116 alongitudinally and circumferentially surrounded by one or more polymerlayers 118, as shown in FIG. 7A. Completed opto-electrical cable 500 fmay include opto-electrical cable core 116 b longitudinally andcircumferentially surrounded by one or more polymer layers 118, as shownin FIG. 7B. Completed opto-electrical cable 500 g may includeopto-electrical cable core 116 c longitudinally and circumferentiallysurrounded by one or more polymer layers 118, as shown in FIG. 7C.Completed opto-electrical cable 500 h may include opto-electrical cablecore 116 e longitudinally and circumferentially surrounded by one ormore polymer layers 118, as shown in FIG. 7D. With references to FIGS.7A-7D, each of completed opto-electrical cables 500 e-500 h may includejacket layer 132 longitudinally and circumferentially surroundingpolymer layers 118. Each jacket layer 132 may include wires 134 encasedwithin polymer 136. Wires 134 may be small served wires. Polymer 136 maybe composed of the same composition as polymer layers 118, or may becomposed of a different composition. For example and without limitation,jacket layer 132 may be at least partially composed of TEFZEL® orcarbon-fiber-reinforced TEFZEL®. While completed opto-electrical cables500 e-500 h are shown as having opto-electrical cables 100 a, 100 b, 100c and 100 e, one skilled in the art with the aid of the presentdisclosure would understand that jacket layer 132 may also be applied toopto-electrical cables 100 d to form a completed opto-electrical cable.

FIGS. 8A, 8B, 8C and 8D depict additional embodiments of completedopto-electrical cables in accordance with this disclosure. Completedopto-electrical cable 500 i may include opto-electrical cable core 116 alongitudinally and circumferentially surrounded by one or more polymerlayers 118, as shown in FIG. 8A. Completed opto-electrical cable 500 jmay include opto-electrical cable core 116 b longitudinally andcircumferentially surrounded by one or more polymer layers 118, as shownin FIG. 8B. Completed opto-electrical cable 500 k may includeopto-electrical cable core 116 c longitudinally and circumferentiallysurrounded by one or more polymer layers 118, as shown in FIG. 8C.Completed opto-electrical cable 500 l may include opto-electrical cablecore 116 e longitudinally and circumferentially surrounded by one ormore polymer layers 118, as shown in FIG. 8D. With reference to FIGS.8A-8D, each completed opto-electrical cable 500 i-500 l may include twoarcuate metal wires 138 a and 138 b, forming a tube longitudinally andcircumferentially surrounding polymer layers 118. Arcuate metal wires138 a and 138 b may be composed of the same or different conductivemetal as base wire 104. Each completed opto-electrical cable 500 i-500 lmay include second polymer layer 118 a longitudinally andcircumferentially surrounding and encasing arcuate metal wires 138 a and138 b. Second polymer layer 118 a may be composed of the same ordifferent composition as polymer layers 118. In operation, wire (e.g.,104, 104 a-104 e) may prevent the tube formed by arcuate metal wires 138a and 138 b from flattening under compressive forces. Seam 140 betweenarcuate metal wires 138 a and 138 b may be aligned with a solid portionof wire (e.g., 104, 104 a-104 e). For example and without limitation,seam 140 may be aligned with a portion of wire (e.g., 104, 104 a-104 e)that does not have a channel located on a circumference of wire (e.g.,104, 104 a-104 e), or seam 140 may be aligned with a portion of wire(e.g., 104, 104 a-104 e) that does not have a wire seam, such as wireseam 141 between base wire 104 and cap wire 104 a. Without being boundby theory, with seam 140 aligned with a solid portion of wire (e.g.,104, 104 a-104 e), shifting of wire (e.g., 104, 104 a-104 e) may beprevented or reduced, preventing or reducing the occurrence of milking.In operation, arcuate metal wires 138 a and 138 b may transmit data,electricity, or combinations thereof. While completed opto-electricalcables 500 i-500 l are shown as having opto-electrical cables 100 a, 100b, 100 c and 100 e, one skilled in the art with the aid of the presentdisclosure would understand that arcuate metal wires 138 and secondpolymer layer 118 a may also be applied to opto-electrical cables 100 dto form a completed opto-electrical cable.

FIGS. 9A, 9B, 9C and 9D depict additional embodiments of completedopto-electrical cables in accordance with this disclosure. Completedopto-electrical cable 500 m may include opto-electrical cable core 116 alongitudinally and circumferentially surrounded by one or more polymerlayers 118, as shown in FIG. 9A. Completed opto-electrical cable 500 nmay include opto-electrical cable core 116 b longitudinally andcircumferentially surrounded by one or more polymer layers 118, as shownin FIG. 9B. Completed opto-electrical cable 500 o may includeopto-electrical cable core 116 c longitudinally and circumferentiallysurrounded by one or more polymer layers 118, as shown in FIG. 9C.Completed opto-electrical cable 500 p may include opto-electrical cablecore 116 e longitudinally and circumferentially surrounded by one ormore polymer layers 118, as shown in FIG. 9D. With references to FIGS.9A-9D, each completed opto-electrical cable 500 m-500 p may includemetallic tape 142 longitudinally and circumferentially surroundingpolymer layers 118. Metallic tape 142 may have longitudinally crimpedseam 144, where two ends of metallic tape 142 are crimped together afterwrapping metallic tape 142 about polymer layers 118. Each completedopto-electrical cables 500 m-500 p may include additional layer ofpolymer 118 b longitudinally and circumferentially surrounding metallictape 142. Additional layer of polymer 118 b may be composed of the sameor different composition as polymer layers 118. While completedopto-electrical cables 500 m-500 p are shown as having opto-electricalcables 100 a, 100 b, 100 c and 100 e, one skilled in the art with theaid of the present disclosure would understand that metallic tape 142and additional layer of polymer 118 b may also be applied toopto-electrical cables 100 d to form a completed opto-electrical cable.

FIGS. 10A-10D depict additional embodiments of completed opto-electricalcables in accordance with this disclosure. Completed opto-electricalcable 500 q may include opto-electrical cable 100 a, as shown in FIG.10A. Completed opto-electrical cable 500 r may include opto-electricalcable 100 b, as shown in FIG. 10B. Completed opto-electrical cable 500 smay include opto-electrical cable 100 c, as shown in FIG. 10C. Completedopto-electrical cable 500 t may include opto-electrical cable 100 e, asshown in FIG. 10D. With reference to FIGS. 10A-10D, each of completedopto-electrical cables 500 q-500 t may include soft polymer layer 200longitudinally and circumferentially surrounding opto-electrical cable100 a, 100 b, 100 c and 100 e, respectively. For example and withoutlimitation, soft polymer layer 200 may be a silicone polymer layer. Eachof completed opto-electrical cables 500 q-500 t may include a pluralityof arch-profile wires 210 longitudinally and circumferentiallysurrounding soft polymer layer 200. Arch-profile wires 210 may provide asolid surface over seams and/or channels 106 of opto-electrical cable100 a, 100 b, 100 c and 100 e, respectively. For example and withoutlimitation, arch-profile wires 210 may be composed of copper,copper-coated steel, or nickel coated copper. In certain embodiments, aportion of soft polymer layer 200 a fills interstitial spaces betweenarch-profile wires 210. In some embodiments, a powder (not shown) may belocated on soft polymer layer 200. Each of completed opto-electricalcables 500 q-500 t may include layer of stranded wires 220 encasedwithin one or more additional layers of polymer 230 and surroundingarch-profile wires 210. Each of completed opto-electrical cables 500q-500 t may have a coaxial cable configuration. Additional layers ofpolymer 230 may be composed of a material that is the same as ordifferent than polymer layer 118. In operation, arch-profile wires 210may transmit data, electricity, or combinations thereof.

FIGS. 11A-11D depict manufacture of completed opto-electrical cable 500q in accordance with this disclosure. While manufacture of completedopto-electrical cable 500 q is described with respect to opto-electricalcable 100 a, one skilled in the art with the aid of the presentdisclosure would understand that the same manufacturing method ofcompleted opto-electrical cable 500 q may be performed with respect toopto-electrical cables 100 b, 100 c, 100 d and 100 e. Opto-electricalcable 100 a may be provided, as shown in FIG. 11A. Soft polymer layer200 may be extruded over opto-electrical cable 100 a to longitudinallyand circumferentially surround and encase polymer layers 118 ofopto-electrical cable 100 a, as shown in FIG. 11B. A plurality ofarch-profile wires 210 may be applied to longitudinally andcircumferentially surround soft polymer layer 200, as shown in FIG. 11C.In certain embodiments, when applying arch-profile wires 210 onto softpolymer layer 200, arch-profile wires 210 may compress over soft polymerlayer 200, causing a portion of soft polymer layer 200 a to fill theinterstitial spaces between arch-profile wires 210. In some embodiments,a powder (not shown) may be applied on soft polymer layer 200. Withoutbeing bound by theory, it is believed that powder on soft polymer layer200 may reduce or prevent metal of arch-profile wires 210 from stickingonto soft polymer layer 200. Layer of stranded wires 220 encased withinone or more additional layers of polymer 230 may be applied to encasearch-profile wires 210, forming completed opto-electrical cable 500 q.

Embodiments of the present disclosure may include a multi-componentcable. FIG. 12 depicts an embodiment of a multi-component cable inaccordance with this disclosure. Multi-component cable 300 may includeone or more completed opto-electrical cables 500 (e.g., 500 a-500 t) andone or more electrical conductor cables 302. Electrical conductor cables302 may include one or more metallic conductor wires (not shown), whichmay be circumferentially and longitudinally surrounded by one or moreinsulation layers (not shown), such as one or more polymer layers. Themetallic conductor wires of electrical conductor cables 302 may becomposed of copper, copper-coated steel, or nickel coated copper, forexample. In operation, electrical conductor cables 302 may provideelectrical power to downhole tools within a wellbore. One or more layersof deformable polymer 304 may longitudinally and circumferentiallysurround completed opto-electrical cables 500 and electrical conductorcables 302. For example and without limitation, deformable polymer 304may be extruded over completed opto-electrical cables 500 and electricalconductor cables 302, encasing completed opto-electrical cables 500 andelectrical conductor cables 302. In certain embodiments, completedopto-electrical cables 500 and electrical conductor cables 302 arearranged within deformable polymer 304 in a coax configuration, a triadconfiguration, a quad configuration, or a hepta configuration. FIG. 12depicts completed opto-electrical cables 500 and electrical conductorcables 302 arranged in a hepta configuration.

In certain embodiments multi-component cable 300 is a jacketed. FIGS.13A-13C depict embodiments of a jacketed multi-component cable inaccordance with this disclosure. FIG. 13A depicts jacketedmulti-component cable 400 a having a hepta configuration. FIG. 13Bdepicts jacketed multi-component cable 400 b having a triadconfiguration. FIG. 13C depicts jacketed multi-component cable 400 chaving a quad configuration. Referring to FIGS. 13A-13C, each ofjacketed multi-component cables 400 a-400 c may include a plurality ofarch-profile wires 310 longitudinally and circumferentially surroundingmulti-component cable 300. Each of jacketed multi-component cables 400a-400 c may include one or more layers of reinforced polymer 314longitudinally and circumferentially surrounding arch-profile wires 310.Reinforced polymer 314 may be composed of a carbon-fiber reinforcedpolymer. Reinforced polymer 314 may encase arch-profile wires 310 andretain arch-profile wires 310 in place about multi-component cable 300,such as during manufacturing and/or deployment (e.g., in a wellbore). Inoperation, under compressive forces during deployment of multi-componentcable 300, arch-profile wires 310 may form a continuous archcircumferentially about multi-component cable 300, dispersing thecompressive forces about the circumference of multi-component cable 300,preventing or reducing the occurrence of milking. Arch-profile wires 310may be composed of copper, copper-coated steel, or nickel coated copper,for example and without limitation. Each of jacketed multi-componentcables 400 a-400 c may include one or more layers of armor wires. Forexample each of jacketed multi-component cables 400 a-400 c may includeinner layer of armor wires 360 and outer layer of armor wires 370. Incertain embodiments, inner layer of armor wires 360 may be cabledhelically over multi-component cable 300. In some embodiments, outerlayer of armor wires 370 may be cabled counter-helically to inner layerof armor wires 360. In some embodiments, the armor wires of inner layerof armor wires 360 and outer layer of armor wires 370 may be composed ofgalvanized improved plow steel (GIPS) or alloy wires for improvedcorrosion resistance, such as a nickel-cobalt-chromium-molybdenum alloy(e.g., MP35N®), a molybdenum containing stainless steel alloy (e.g.,INCOLOY® 27-7MO), or a nickel containing steel alloy (e.g., HC265).

FIGS. 14A-14H depict manufacture of jacketed multi-component 400 a inaccordance with this disclosure. Multi-component cable 300 is provided,as shown in FIG. 14A, and arch-profile wires 310 are provided, as shownin FIG. 14B. Arch-profile wires 310 are at least partially embedded intodeformable polymer 304, as shown in FIG. 14C. In some embodiments, aportion of deformable polymer 304 a fills interstitial spaces betweenarch-profile wires 310. After being applied over deformable polymer 304,edges 312 of arch-profile wires 310 are in contact with one another,forming a compression-resistant barrier over multi-component cable 300.First layer of reinforced polymer 314 a may longitudinally andcircumferentially surround arch-profile wires 310, as shown in FIG. 14D.For example and without limitation, first layer of reinforced polymer314 a may be extruded over arch-profile wires 310, encasing arch-profilewires 310. Inner layer of armor wires 360 may longitudinally andcircumferentially surround reinforced polymer 314 a, as shown in FIG.14E. In certain embodiments, inner layer of armor wires 360 may be atleast partially embedded into reinforced polymer 314 a. For example andwithout limitation, inner layer of armor wires 360 may be applied toreinforced polymer 314 a while reinforced polymer 314 a is in a pliablestate, such as after extrusion of reinforced polymer 314 a or afterpassing multi-component cable 300 with reinforced polymer 314 a throughan infrared 362 heating source. Second layer of reinforced polymer 314 bmay surround inner layer of armor wires 360, as shown in FIG. 14F. Forexample and without limitation, second layer of reinforced polymer 314 bmay be extruded over inner layer of armor wires 360, encasing innerlayer of armor wires 360. Reinforced polymer 314 b may bond withreinforced polymer 314 a through the interstitial spaces between thewires of inner layer of armor wires 360. Reinforced polymer 314 b maylongitudinally and circumferentially surround inner layer of armor wires360. Outer layer of armor wires 370 may be partially embedded intoreinforced polymer 314 b, as shown in FIG. 14G. Outer layer of armorwires 370 may longitudinally and circumferentially surround reinforcedpolymer 314 b. For example and without limitation, while reinforcedpolymer 314 b is in a pliable state, outer layer of armor wires 370 maybe partially embedded into reinforced polymer 314 b. Reinforced polymer314 b may be in a pliable state after extrusion of second layer ofreinforced polymer 314 b or after passing multi-component cable 300 withreinforced polymer 314 b through infrared 362 heating source, forexample. Third layer of reinforced polymer 314 c may longitudinally andcircumferentially surround outer layer of armor wires 370, as shown inFIG. 14H. Reinforced polymer 314 c may bond with reinforced polymer 314b through interstitial spaces between the armor wires of outer layer ofarmor wires 370, encasing outer layer of armor wires 370.

FIGS. 15A-15C depict additional embodiments of jacketed multi-componentcables in accordance with this disclosure. FIG. 15A depicts jacketedmulti-component cable 400 d having a hepta configuration. FIG. 15Bdepicts jacketed multi-component cable 400 e having a quadconfiguration. FIG. 15C depicts jacketed multi-component cable 400 fhaving a triad configuration. With reference to FIGS. 15A-15C, each ofjacketed multi-component cables 400 d-400 f include one or more layersof corrugated metallic tape 320 longitudinally and circumferentiallysurrounding multi-component cable 300. Corrugated metallic tape 320 maybe compression resistant, and may be adapted to bend over radii, such asspools and sheaves. Each of jacketed multi-component cables 400 d-400 fmay include one or more layers of reinforced polymer 314 longitudinallyand circumferentially surrounding layer of corrugated metallic tape 320.Reinforced polymer 314 may encase layer of corrugated metallic tape 320and retain layer of corrugated metallic tape 320 in place aboutmulti-component cable 300, such as during manufacturing and/ordeployment (e.g., in a wellbore). In operation, deformable polymer 304(not shown) may cushion multi-component cable 300 against compressiveforces, and reinforced polymer 314 may cushion multi-component cable 300against compressive forces and form a circular-profile. In certainembodiments, layer of corrugated metallic tape 320 protectsmulti-component cable 300 against compressive forces and enhancesflexibility of multi-component cable 300, preventing or reducing theoccurrence of milking. Each of jacketed multi-component cables 400 d-400f may include one or more layers of armor wires. For example, each ofjacketed multi-component cables 400 d-400 f may include inner layer ofarmor wires 360 and outer layer of armor wires 370. In certainembodiments, inner layer of armor wires 360 may be cabled helically overmulti-component cable 300. In some embodiments, outer layer of armorwires 370 may be cabled counter-helically to inner layer of armor wires360.

FIGS. 16A-16I depict manufacture of jacketed multi-component 400 d inaccordance with this disclosure. Multi-component cable 300 is provided,as shown in FIG. 16A. Corrugated metallic tape 320 having sides 319 isprovided, as shown in FIG. 16B. Corrugated metallic tape 320 may bewrapped longitudinally and circumferentially about deformable polymer304, as shown in FIGS. 16C and 16D. Sides 319 of corrugated metallictape 320 (shown in FIG. 16B) may be overlapped with one another,providing complete or substantially complete coverage overmulti-component cable 300. In certain embodiments, layer of corrugatedmetallic tape 320 is at least partially embedded into deformable polymer304. In certain embodiments, layer of corrugated metallic tape 320 iswrapped about two layers of deformable polymer 304. Layer of corrugatedmetallic tape 320 may form a tube about multi-component cable 300. Firstlayer of reinforced polymer 314 a may longitudinally andcircumferentially surround layer of corrugated metallic tape 320, asshown in FIG. 16E. For example and without limitation, first layer ofreinforced polymer 314 a may be extruded over layer of corrugatedmetallic tape 320, encasing layer of corrugated metallic tape 320. Firstlayer of reinforced polymer 314 a may form a circular-profile, aiding insubsequent manufacturing steps. Inner layer of armor wires 360 maylongitudinally and circumferentially surround reinforced polymer 314 a,as shown in FIG. 16F. In certain embodiments, inner layer of armor wires360 may be at least partially embedded into reinforced polymer 314 a.For example and without limitation, inner layer of armor wires 360 maybe applied to reinforced polymer 314 a while reinforced polymer 314 a isin a pliable state, such as after extrusion of reinforced polymer 314 aor after passing multi-component cable 300 with reinforced polymer 314 athrough an infrared 362 heating source. Second layer of reinforcedpolymer 314 b may surround inner layer of armor wires 360, as shown inFIG. 16G. For example and without limitation, second layer of reinforcedpolymer 314 b may be extruded over inner layer of armor wires 360,encasing inner layer of armor wires 360. Reinforced polymer 314 b maybond with reinforced polymer 314 a through the interstitial spacesbetween the wires of inner layer of armor wires 360. Reinforced polymer314 b may longitudinally and circumferentially surround inner layer ofarmor wires 360. Outer layer of armor wires 370 may be partiallyembedded into reinforced polymer 314 b, as shown in FIG. 16H. Outerlayer of armor wires 370 may longitudinally and circumferentiallysurround reinforced polymer 314 b. For example and without limitation,while reinforced polymer 314 b is in a pliable state, outer layer ofarmor wires 370 may be partially embedded into reinforced polymer 314 b.Reinforced polymer 314 b may be in a pliable state after extrusion ofsecond layer of reinforced polymer 314 b or after passingmulti-component cable 300 with reinforced polymer 314 b through infrared362 heating source, for example. Third layer of reinforced polymer 314 cmay longitudinally and circumferentially surround outer layer of armorwires 370, as shown in FIG. 16I. Reinforced polymer 314 c may bond withreinforced polymer 314 b through interstitial spaces between the armorwires of outer layer of armor wires 370, encasing outer layer of armorwires 370.

FIGS. 17A-17C depict additional embodiments of jacketed multi-componentcables in accordance with this disclosure. FIG. 17A depicts jacketedmulti-component cable 400 g having a hepta configuration. FIG. 17Bdepicts jacketed multi-component cable 400 h having a quadconfiguration. FIG. 17C depicts jacketed multi-component cable 400 ihaving a triad configuration. With reference to FIGS. 17A-17C, eachjacketed multi-component cable 400 g-400 i may include a layer ofmetallic cladding tape 330 longitudinally and circumferentiallysurrounding multi-component cable 300. Metallic cladding tape 330 mayform a tube (e.g., corrugated tube) longitudinally and circumferentiallyabout multi-component cable 300, which may be compression-resistant andadapted to bend over radii, such as spools and sheaves. Each jacketedmulti-component cable 400 g-400 i may include one or more layers ofreinforced polymer 314 longitudinally and circumferentially surroundingmetallic cladding tape 330. In operation, under compressive forcesduring deployment of multi-component cable 300, metallic cladding tape330 may form a compression-resistant tube, distributing the compressiveforces circumferentially about multi-component cable 300, preventing orreducing the occurrence of milking. Each of jacketed multi-componentcables 400 g-400 i may include one or more layers of armor wires. Forexample, each of jacketed multi-component cables 400 g-400 i may includeinner layer of armor wires 360 and outer layer of armor wires 370. Incertain embodiments, inner layer of armor wires 360 may be cabledhelically over multi-component cable 300. In some embodiments, outerlayer of armor wires 370 may be cabled counter-helically to inner layerof armor wires 360.

FIGS. 18A-18H depict manufacture of jacketed multi-component cables 400g in accordance with this disclosure. Multi-component cable 300 may beprovided, as shown in FIG. 18A. Metallic cladding tape 330 may bewrapped about multi-component cable 300 to longitudinally andcircumferentially surround deformable polymer 304, as shown in FIGS. 18Band 18C. In certain embodiments, metallic cladding tape 330 may bewrapped helically over deformable polymer 304. Deformable polymer 304may encase metallic cladding tape 330 and retain metallic cladding tape330 in place during manufacturing and/or during deployment (e.g., in awellbore) of multi-component cable 300. Sides 332 of metallic claddingtape 330 may be overlapped, providing complete or substantiallycomplement coverage of multi-component cable 300. First layer ofreinforced polymer 314 a may longitudinally and circumferentiallysurround metallic cladding tape 330, as shown in FIG. 18D. For exampleand without limitation, first layer of reinforced polymer 314 a may beextruded over metallic cladding tape 330, encasing metallic claddingtape 330. Reinforced polymer 314 a may retain metallic cladding tape 330in place about multi-component cable 300, such as during manufacturingand/or deployment (e.g., in a wellbore). Inner layer of armor wires 360may longitudinally and circumferentially surround reinforced polymer 314a, as shown in FIG. 18E. In certain embodiments, inner layer of armorwires 360 may be at least partially embedded into reinforced polymer 314a. For example and without limitation, inner layer of armor wires 360may be applied to reinforced polymer 314 a while reinforced polymer 314a is in a pliable state, such as after extrusion of reinforced polymer314 a or after passing multi-component cable 300 with reinforced polymer314 a through an infrared 362 heating source. Second layer of reinforcedpolymer 314 b may surround inner layer of armor wires 360, as shown inFIG. 18F. For example and without limitation, second layer of reinforcedpolymer 314 b may be extruded over inner layer of armor wires 360,encasing inner layer of armor wires 360. Reinforced polymer 314 b maybond with reinforced polymer 314 a through the interstitial spacesbetween the wires of inner layer of armor wires 360. Reinforced polymer314 b may longitudinally and circumferentially surround inner layer ofarmor wires 360. Outer layer of armor wires 370 may be partiallyembedded into reinforced polymer 314 b, as shown in FIG. 18G. Outerlayer of armor wires 370 may longitudinally and circumferentiallysurround reinforced polymer 314 b. For example and without limitation,while reinforced polymer 314 b is in a pliable state, outer layer ofarmor wires 370 may be partially embedded into reinforced polymer 314 b.Reinforced polymer 314 b may be in a pliable state after extrusion ofsecond layer of reinforced polymer 314 b or after passingmulti-component cable 300 with reinforced polymer 314 b through infrared362 heating source, for example. Third layer of reinforced polymer 314 cmay longitudinally and circumferentially surround outer layer of armorwires 370, as shown in FIG. 18H. Reinforced polymer 314 c may bond withreinforced polymer 314 b through interstitial spaces between the armorwires of outer layer of armor wires 370, encasing outer layer of armorwires 370.

FIGS. 19A-19C depict additional embodiments of jacketed multi-componentcables in accordance with this disclosure. FIG. 19A depicts jacketedmulti-component cable 400 j having a hepta configuration. FIG. 19Bdepicts jacketed multi-component cable 400 k having a quadconfiguration. FIG. 19C depicts jacketed multi-component cable 400 lhaving a triad configuration. Each jacketed multi-component cable 400j-400 l may include hard polymeric layer 350 longitudinally andcircumferentially surrounding multi-component cable 300. In certainembodiments, hard polymeric layer 350 may be composed ofpolyetheretherketone (PEEK) or another hard polymer. In operation, hardpolymer layer 350 may encase multi-component cable 300 and protectmulti-component cable 300 against compressive forces during themanufacturing process and deployment operations. Each jacketedmulti-component cable 400 j-400 l may include one or more layers ofreinforced polymer 314 longitudinally and circumferentially surroundinghard polymeric layer 350. Each of jacketed multi-component cables 400j-400 l may include one or more layers of armor wires. For example, eachof jacketed multi-component cables 400 j-400 l may include inner layerof armor wires 360 and outer layer of armor wires 370. In certainembodiments, inner layer of armor wires 360 may be cabled helically overmulti-component cable 300. In some embodiments, outer layer of armorwires 370 may be cabled counter-helically to inner layer of armor wires360.

FIGS. 20A-20G depict manufacture of jacketed multi-component cables 400j in accordance with this disclosure. Multi-component cable 300 may beprovided, as shown in FIG. 20A. Hard polymeric layer 350 may be extrudedover deformable polymer 304, encasing deformable polymer 304. Firstlayer of reinforced polymer 314 a may be extruded over hard polymericlayer 350, encasing hard polymeric layer 350. Inner layer of armor wires360 may longitudinally and circumferentially surround reinforced polymer314 a, as shown in FIG. 20D. In certain embodiments, inner layer ofarmor wires 360 may be at least partially embedded into reinforcedpolymer 314 a. For example and without limitation, inner layer of armorwires 360 may be applied to reinforced polymer 314 a while reinforcedpolymer 314 a is in a pliable state, such as after extrusion ofreinforced polymer 314 a or after passing multi-component cable 300 withreinforced polymer 314 a through an infrared 362 heating source. Secondlayer of reinforced polymer 314 b may surround inner layer of armorwires 360, as shown in FIG. 20E. For example and without limitation,second layer of reinforced polymer 314 b may be extruded over innerlayer of armor wires 360, encasing inner layer of armor wires 360.Reinforced polymer 314 b may bond with reinforced polymer 314 a throughthe interstitial spaces between the wires of inner layer of armor wires360. Reinforced polymer 314 b may longitudinally and circumferentiallysurround inner layer of armor wires 360. Outer layer of armor wires 370may be partially embedded into reinforced polymer 314 b, as shown inFIG. 20F. Outer layer of armor wires 370 may longitudinally andcircumferentially surround reinforced polymer 314 b. For example andwithout limitation, while reinforced polymer 314 b is in a pliablestate, outer layer of armor wires 370 may be partially embedded intoreinforced polymer 314 b. Reinforced polymer 314 b may be in a pliablestate after extrusion of second layer of reinforced polymer 314 b orafter passing multi-component cable 300 with reinforced polymer 314 bthrough infrared 362 heating source, for example. Third layer ofreinforced polymer 314 c may longitudinally and circumferentiallysurround outer layer of armor wires 370, as shown in FIG. 20G.Reinforced polymer 314 c may bond with reinforced polymer 314 b throughinterstitial spaces between the armor wires of outer layer of armorwires 370, encasing outer layer of armor wires 370.

In operation, multi-component cable 300 or jacketed multi-componentcables 400 a-400 j may provide one or more low voltage paths viaelectrical conductor cables 302 and/or wires (e.g., 104, 104 a-104 e),one or more telemetry paths via fiber optic cables 110 and/or wires(e.g., 104, 104 a-104 e), one or more high voltage electrical paths viaelectrical conductor cables 302 and/or wires (e.g., 104, 104 a-104 e),or combinations thereof. In certain embodiments, such as the quadconfiguration, multi-component cable 300 or jacketed multi-componentcables 400 a-400 j may supply AC power to downhole tools.

In certain embodiments, multi-component cable 300 or jacketed cables 400a-400 j may be used with wellbore devices to perform operations inwellbores penetrating geologic formations that may contain gas and oilreservoirs. Multi-component cable 300 or jacketed multi-component cables400 a-400 j may be used to interconnect well logging tools, such asgamma-ray emitters/receivers, caliper devices, resistivity-measuringdevices, seismic devices, neutron emitters/receivers, downhole tractors,mechanical service tools, and the like, to one or more power suppliesand data logging equipment outside the well. Multi-component cable 300or jacketed multi-component cables 400 a-400 j may be used in seismicoperations, including subsea and subterranean seismic operations.Multi-component cable 300 or jacketed multi-component cables 400 a-400 jmay be used as permanent monitoring cables for wellbores.

EXAMPLES

The disclosure having been generally described, the following examplesshow particular embodiments of the disclosure. It is understood that theexample is given by way of illustration and is not intended to limit thespecification or the claims.

Example 1—Manufacturing Process—Channel and Cap Configuration

The manufacture of an opto-electrical cable having a channel and capconfiguration may proceed as follows:

-   -   1. A first conductive metal wire having a        partial-circular-profile is provided. One side of the first        conducted metal wire is planar, with a channel running        longitudinally along the planar side.    -   2. One or more optical fibers are placed into the channel.    -   3. Soft gel filler is placed into the channel, encasing the one        or more optical fibers and serving as a protective cushion.    -   4. A second conductive metal wire is provided. The second        conductive metal wire has a semicircular outer profile and a tab        sized to fit within the channel in the first conductive metal        wire.    -   5. The second conductive metal wire is fitted into the first        conductive metal wire to form an opto-electrical cable core.    -   6. A layer of tape (e.g., PEEK) is applied over the        opto-electrical cable core to form an opto-electrical cable.        Alternatively, a layer of polymer is extruded over the        opto-electrical cable core to form the opto-electrical cable.

Example 2—Manufacturing Process—Circular Wire with Multiple Channels

The manufacture of an opto-electrical cable having a wire with multiplechannels may proceed as follows:

-   -   1. A conductive metal wire having a circular-profile with three        or more uniformly spaced channels around the outer diameter of        the conductive metal wire is provided.    -   2. One or more optical fibers are placed in each channel.    -   3. Soft gel filler is placed into each channel, encasing the        optical fibers and serving as a protective cushion to form an        opto-electrical cable core.    -   4. A layer of tape (e.g., PEEK) or polymer extrusion is applied        over the opto-electrical cable core to form an opto-electrical        cable.

Example 3—Manufacturing Process—Circular Wire with a Single Channel

The manufacture of an opto-electrical cable having a wire with a singlechannel may proceed as follows:

-   -   1. A conductive metal wire having a circular-profile with a        single channel located in the outer diameter of the conductive        metal wire is provided.    -   2. One or more optical fibers are placed in the channel.    -   3. Soft gel filler is placed into the channel, encasing the        optical fibers and serving as a protective cushion to form an        opto-electrical cable core.    -   4. A layer of tape (e.g., PEEK) or polymer extrusion is applied        over the opto-electrical cable core to form an opto-electrical        cable.

Example 4—Manufacturing Process—Hexagonal Wire with a Flat Base andSingle Channel

The manufacture of an opto-electrical cable having a hexagonal wire witha single channel may proceed as follows:

-   -   1. A conductive metal wire having an approximately        hexagonal-profile with a single channel located in the outer        diameter of the conductive metal wire, a planar base opposite        the single channel, and at least partially flattened sides is        provided.    -   2. The conductive metal wire is held in place upon the planar        base, optionally by holding the at least partially flattened        sides.    -   3. One or more optical fibers are placed in the channel.    -   4. Soft gel filler is placed into the channel, encasing the        optical fibers and serving as a protective cushion to form an        opto-electrical cable core.    -   5. A layer of tape (e.g., PEEK) or polymer extrusion is applied        over the opto-electrical cable core to form an opto-electrical        cable and provide the opto-electrical cable with a        circular-profile.

Example 5—Manufacturing Process—C-Shaped Wire with a Single Channel

The manufacture of an opto-electrical cable having a C-shaped wire witha single channel may proceed as follows:

-   -   1. A conductive metal wire having a C-shaped-profile and an        interior that forms a channel running the length of the        conductive metal wire is provided.    -   2. One or more optical fibers are placed in the channel.    -   3. Soft gel filler is placed into the channel, encasing the        optical fibers and serving as a protective cushion.    -   4. A plug is placed into an opening of the channel to seal the        soft gel filler within the channel and form an opto-electrical        cable core. A gel or other material that forms the plug may form        a thin layer over the outer surface of the conductive metal        wire.    -   5. A layer of tape (e.g., PEEK) or polymer extrusion is applied        over the opto-electrical cable core to form an opto-electrical        cable.

Example 6—Manufacturing Process—Core Completion

Completion of any of the opto-electrical cables of Examples 1-5 to forma completed opto-electrical cable may proceed as follows:

-   -   1. A layer of cladding is applied over an opto-electrical cable        formed in accordance with any of Examples 1-5; or    -   2. A jacket layer is applied over an opto-electrical cable        formed in accordance with any of Examples 1-5. The jacket layer        may include small served wires encased in a polymer layer (e.g.,        TEFZEL® or Carbon-fiber-reinforced TEFZEL1®); or    -   3. Two semi-circular-shaped metallic wires (e.g., arcuate metal        wires) are placed over an opto-electrical cable formed in        accordance with any of Examples 1-5, forming an outer tube,        followed by application of an additional layer of polymer over        the tube; or    -   4. A layer of metallic tape with a longitudinal crimped seam is        applied over an opto-electrical cable formed in accordance with        any of Examples 1-5, followed by application of an additional        layer of polymer over the layer of metallic tape.

Example 7—Manufacturing Process—Coaxial Core Completion

Completion of any of the opto-electrical cables of Examples 1-5 to forma completed opto-electrical cable may proceed as follows:

-   -   1. An opto-electrical cable formed in accordance with any of        Examples 1-5 is provided.    -   2. A layer of soft silicone polymer is extruded over the        opto-electrical cable. A powder may be placed over the silicone        to alleviate the possibility of the silicone sticking to the        metal in subsequent step 3.    -   3. A number of arch-profile wires are placed over the layer of        soft silicone polymer. As the wires compress over the layer of        soft silicone polymer, the soft silicone polymer fills the        interstitial spaces between the arch-profile wires.    -   4. A layer of stranded wires encased in layers of polymer is        applied over the arch-profile wires to form a completed        opto-electrical cable having a coaxial cable configuration.

Example 8—Manufacturing Process—Arch-Profile Wire Jacketing

A completed opto-electrical cable formed in accordance with eitherExample 6 or 7 may be arranged into a jacketed multi-component cable asfollows:

-   -   1. A layer of soft, deformable polymer is applied over one or        more completed opto-electrical cables formed in accordance with        Example 6 and/or 7, and one or more electrical conductor cables,        forming a multi-component cable. The completed opto-electrical        cables and electrical conductor cables may have a triad, quad,        or hepta configuration, for example.    -   2. A number of arch-profile metallic wires sufficient to cover        the circumference of the multi-component cable are placed        longitudinally over the multi-component cable.    -   3. The arch-profile wires are embedded into the soft, deformable        polymer. The arch-profile wires are shaped to allow the polymer        to deform into interstitial spaces between the arch-profile        wires. The outer profiles of the arch-profile wires contact each        other and form a compression-resistant barrier over the        multi-component cable.    -   4. A first layer of carbon-fiber-reinforced (CFR) polymer is        extruded over the arch-profile wires to lock the arch-profile        wires in place about the multi-component cable.    -   5. While the first layer of CFR polymer is still pliable or        after passing the multi-component cable through an infrared        heating source, an inner layer of armor wire strength members is        cabled helically over and partially embedded into the first        layer of CFR-polymer.    -   6. A second layer of CFR polymer is extruded over the inner        layer of armor wire strength members and bonds with the first        layer of CFR polymer layer through the interstitial spaces        between the armor wire strength members.    -   7. While the second layer of CFR polymer is still pliable or        after passing the multi-component cable through an infrared        heating source, an outer layer of armor wire strength members is        cabled counter-helically to the inner layer of armor wire        strength members over and is partially embedded into the second        layer of CFR-polymer.    -   8. For additional seal, a final layer of CFR polymer is extruded        over the outer layer of armor wire strength members and bonds        with the second layer of CFR polymer layer through the        interstitial spaces between the armor wire strength members,        forming the jacketed multi-component cable.

Example 9—Manufacturing Process—Corrugated Metallic Tape Jacketing

A completed opto-electrical cable formed in accordance with either ofExample 6 or 7 may be arranged into a jacketed multi-component cable asfollows:

-   -   1. A layer of soft, deformable polymer is applied over one or        more completed opto-electrical cable formed in accordance with        Example 6 and/or 7, and one or more electrical conductor cables,        forming a multi-component cable. The completed opto-electrical        cables and electrical conductor cables may have a triad, quad,        or hepta configuration, for example.    -   2. A corrugated metallic tape is wrapped longitudinally around        and embedded into the soft, deformable polymer to form a        corrugated tube. The sides of the corrugated metallic tape        overlap to ensure complete coverage.    -   3. A first layer of carbon-fiber-reinforced (CFR) polymer is        extruded over the corrugated metallic tape to lock the        corrugated metallic tape in place about the multi-component        cable.    -   4. While the first layer of CFR polymer is still pliable or        after passing the multi-component cable through an infrared        heating source, an inner layer of armor wire strength members is        cabled helically over and partially embedded into the first        layer of CFR-polymer.    -   5. A second layer of CFR polymer is extruded over the inner        layer of armor wire strength members and bonds with the first        layer of CFR polymer layer through the interstitial spaces        between the armor wire strength members.    -   6. While the second layer of CFR polymer is still pliable or        after passing the multi-component cable through an infrared        heating source, an outer layer of armor wire strength members is        cabled counter-helically to the inner layer of armor wire        strength members over and is partially embedded into the second        layer of CFR-polymer.    -   7. For additional seal, a final layer of CFR polymer is extruded        over the outer layer of armor wire strength members and bonds        with the second layer of CFR polymer layer through the        interstitial spaces between the armor wire strength members,        forming the jacketed multi-component cable.

Example 10—Manufacturing Process—Metallic Cladding Tape Jacketing

A completed opto-electrical cable formed in accordance with either ofExample 6 or 7 may be arranged into a jacketed multi-component cable asfollows:

-   -   1. A layer of soft, deformable polymer is applied over one or        more completed opto-electrical cables formed in accordance with        Example 6 and/or 7, and one or more electrical conductor cables,        forming a multi-component cable. The completed opto-electrical        cables and the electrical conductor cables may have a triad,        quad, or hepta configuration, for example.    -   2. A layer of metallic cladding tape is helically wrapped over        the soft, deformable polymer. The sides of the metallic cladding        tape overlap to ensure complete coverage of the multi-component        cable.    -   3. A first layer of carbon-fiber-reinforced (CFR) polymer is        extruded over the metallic cladding tape to lock the metallic        cladding tape in place about the multi-component cable.    -   4. While the first layer of CFR polymer is still pliable or        after passing the multi-component cable through an infrared        heating source, an inner layer of armor wire strength members is        cabled helically over and partially embedded into the first        layer of CFR-polymer.    -   5. A second layer of CFR polymer is extruded over the inner        layer of armor wire strength members and bonds with the first        layer of CFR polymer layer through the interstitial spaces        between the armor wire strength members.    -   6. While the second layer of CFR polymer is still pliable or        after passing the multi-component cable through an infrared        heating source, an outer layer of armor wire strength members is        cabled counter-helically to the inner layer of armor wire        strength members over and is partially embedded into the second        layer of CFR-polymer.    -   7. In some embodiments, for additional seal, a final layer of        CFR polymer is extruded over the outer layer of armor wire        strength members and bonds with the second layer of CFR polymer        layer through the interstitial spaces between the armor wire        strength members, forming the jacketed multi-component cable.

Example 11—Manufacturing Process—PEEK Jacketing

A completed opto-electrical cable formed in accordance with either ofExample 6 or 7 may be arranged into a jacketed multi-component cable asfollows:

-   -   1. A layer of soft, deformable polymer or tape is applied over        one or more completed opto-electrical cables formed in        accordance with Example 6 and/or 7, and one or more electrical        conductor cables, forming a multi-component cable. The completed        opto-electrical cables and the electrical conductor cables may        have a triad, quad, or hepta configuration, for example.    -   2. A thick layer of polyetheretherketone (PEEK) or other hard        polymer is extruded over the soft, deformable polymer or tape.    -   3. A first layer of carbon-fiber-reinforced (CFR) polymer is        extruded over the thick layer of polyetheretherketone (PEEK) or        other hard polymer.    -   4. While the first layer of CFR polymer is still pliable or        after passing the multi-component cable through an infrared        heating source, an inner layer of armor wire strength members is        cabled helically over and partially embedded into the first        layer of CFR-polymer.    -   5. A second layer of CFR polymer is extruded over the inner        layer of armor wire strength members and bonds with the first        layer of CFR polymer layer through the interstitial spaces        between the armor wire strength members.    -   6. While the second layer of CFR polymer is still pliable or        after passing the multi-component cable through an infrared        heating source, an outer layer of armor wire strength members is        cabled counter-helically to the inner layer of armor wire        strength members over and is partially embedded into the second        layer of CFR-polymer.    -   7. In some embodiments, for additional seal, a final layer of        CFR polymer is extruded over the outer layer of armor wire        strength members and bonds with the second layer of CFR polymer        layer through the interstitial spaces between the armor wire        strength members, forming the jacketed multi-component cable.

Depending on the context, all references herein to the “disclosure” mayin some cases refer to certain specific embodiments only. In other casesit may refer to subject matter recited in one or more, but notnecessarily all, of the claims. While the foregoing is directed toembodiments, versions and examples of the present disclosure, which areincluded to enable a person of ordinary skill in the art to make and usethe disclosures when the information in this patent is combined withavailable information and technology, the disclosures are not limited toonly these particular embodiments, versions and examples. Other andfurther embodiments, versions and examples of the disclosure may bedevised without departing from the basic scope thereof and the scopethereof is determined by the claims that follow.

What is claimed is:
 1. A method comprising: providing a wire, whereinone or more channels are formed within the wire and extend along alongitudinal axis of the wire; providing one or more optical fibersextending longitudinally within each channel to form an opto-electricalcable core; and applying a polymer layer longitudinally andcircumferentially surrounding the opto-electrical cable core to form anopto-electrical cable; wherein the wire comprises a base wire, whereinone channel is formed within the base wire between two portions of abase wire mating face of the base wire and extends along thelongitudinal axis the base wire, and wherein the method furthercomprises, prior to applying the polymer layer: providing a cap wirecomprising a tab formed between two portions of a cap wire mating faceof the cap wire, wherein the tab extends from the cap wire matingsurface; and mechanically coupling the tab within the channel of thebase wire to enclose the channel.
 2. The method of claim 1, furthercomprising, prior to applying the polymer layer, encasing the one ormore optical fibers within each channel with a filler.
 3. A methodcomprising: providing a wire, wherein one or more channels are formedwithin the wire and extend along a longitudinal axis of the wire;providing one or more optical fibers extending longitudinally withineach channel to form an opto-electrical cable core; and applying apolymer layer longitudinally and circumferentially surrounding theopto-electrical cable core to form an opto-electrical cable; wherein thewire comprises one channel formed within a central interior of the wireand extending along the longitudinal axis of the wire, wherein the onechannel comprises an opening formed between two portions of an outerwire circumference of the wire, and wherein the method comprises:encasing the one or more optical fibers within the one channel with afiller; and mechanically coupling or chemically bonding a plug with thewire at the opening of the one channel to enclose the one channel.
 4. Amethod comprising: providing a wire, wherein one or more channels areformed within the wire and extend along a longitudinal axis of the wire;providing one or more optical fibers extending longitudinally withineach channel to form an opto-electrical cable core; and applying apolymer layer longitudinally and circumferentially surrounding theopto-electrical cable core to form an opto-electrical cable; wherein thewire comprises a base formed along an outer wire circumference of thewire and extending along the longitudinal axis of the wire and onechannel formed between two portions of the outer circumference of thewire and extending along the longitudinal axis of the wire opposite thebase, and wherein the method comprises holding the wire in a position onthe base while providing the one or more optical fibers extendinglongitudinally within the one channel.
 5. A method comprising: providinga wire, wherein one or more channels are formed within the wire andextend along a longitudinal axis of the wire; providing one or moreoptical fibers extending longitudinally within each channel to form anopto-electrical cable core; applying a polymer layer longitudinally andcircumferentially surrounding the opto-electrical cable core to form anopto-electrical cable; and applying one or more completion layerslongitudinally and circumferentially surrounding the polymer layer,wherein the one or more completion layers comprise: a layer of claddinglongitudinally and circumferentially surrounding the polymer layer; or ajacket layer longitudinally and circumferentially surrounding thepolymer layer, wherein the jacket layer comprises wires encased within apolymer; or a tube longitudinally and circumferentially surrounding thepolymer layer, wherein the tube comprises two arcuate metal wires, and asecond polymer layer longitudinally and circumferentially surroundingthe tube; or a metallic tape longitudinally and circumferentiallysurrounding the polymer layer, wherein the metallic tape comprises alongitudinally crimped seam; or a soft polymer layer longitudinally andcircumferentially surrounding the polymer layer, a plurality ofarch-profile wires longitudinally and circumferentially surrounding thesoft polymer layer, wherein a portion of the soft polymer layer fillsinterstitial spaces between the arch-profile wires, and a layer ofstranded wires encased within one or more additional layers of polymerlongitudinally and circumferentially surrounding the plurality ofarch-profile wires.
 6. The method of claim 5, further comprising:providing one or more electrical conductor cables; providing one or moreof the opto-electrical cables; arranging the one or more opto-electricalcables and the one or more electrical conductor cable cores in a coaxconfiguration, a triad configuration, a quad configuration, or a heptaconfiguration; and applying one or more layers of deformable polymerlongitudinally and circumferentially surrounding the one or moreopto-electrical cables and the one or more electrical conductor cables.7. The method of claim 6, further comprising applying a first jacketinglayer longitudinally and circumferentially surrounding the one or morelayers of deformable polymer; applying a first layer of reinforcedpolymer longitudinally and circumferentially surrounding the firstjacketing layer, wherein an inner layer of armor wires is partiallyembedded into the first layer of reinforced polymer; applying a secondlayer of reinforced polymer longitudinally and circumferentiallysurrounding the inner layer of armor wires, wherein the second layer ofreinforced polymer bonds with the first layer of reinforced polymerthrough interstitial spaces between the armor wires of the inner layerof armor wires, and wherein an outer layer of armor wires is partiallyembedded into the second layer of reinforced polymer; and optionallyapplying a third layer of reinforced polymer longitudinally andcircumferentially surrounding the outer layer of armor wire, wherein thethird layer of reinforced polymer bonds with the second layer ofreinforced polymer through interstitial spaces between the armor wiresof the outer layer of armor wires.
 8. The method of claim 7, wherein thefirst jacketing layer comprises: a plurality of arch-profile wireslongitudinally and circumferentially surrounding the one or more layersof deformable polymer, wherein a portion of the one or more layers ofdeformable polymer fills interstitial spaces between the arch-profilewires; or a layer of corrugated metallic tape longitudinally andcircumferentially surrounding the one or more layers of deformablepolymer, wherein the layer of corrugated metallic tape is at leastpartially embedded into the one or more layers of deformable polymer; ora layer of metallic cladding tape longitudinally and circumferentiallysurrounding the one or more layers of deformable polymer; or a hardpolymeric layer longitudinally and circumferentially surrounding the oneor more layers of deformable polymer.
 9. The method of claim 4, furthercomprising, prior to applying the polymer layer, encasing the one ormore optical fibers within each channel with a filler.